Forklifts, Hoisting, Rigging, and Material Handling

Moving materials changes the hazard picture

Forklifts, cranes, hoists, slings, carts, conveyors, pallet jacks, and fleet vehicles can expose people to struck-by, caught-between, crushed-by, tip-over, dropped-load, visibility, and stability hazards. Material handling programs should address operator competence, equipment inspection, load planning, traffic routes, pedestrian separation, communication, maintenance, and incident review.

Forklift safety is not just an operator issue. The site layout, aisle width, floor condition, blind corners, dock condition, rack stability, lighting, pedestrian crossings, charging or fueling area, speed expectations, and load storage all affect risk. A careful operator can still be placed in a poor system if pedestrians work in the same aisle without barriers or traffic rules.

Powered industrial truck inspection should occur under the site program before operation. Defects that affect safe operation should be reported and corrected before use. Operators should understand the truck type, attachments, rated capacity, stability triangle concepts, surface conditions, ramps, load height, and visibility limitations. Attachments can change capacity and center of gravity, so they must be considered in planning.

Hoisting and rigging require a different set of controls. The team must know the load weight, center of gravity, attachment points, sling or hardware capacity, sling angle effects, sharp edges, hitch type, load path, hand signals or radio communication, wind or weather limits, and where people will stand. Never stand under a suspended load or place body parts where a shifting load can crush them.

Rigging inspection is critical. Damaged slings, distorted hooks, missing identification, severe wear, heat damage, chemical damage, broken wires, or incompatible hardware can create failure. The program should define who may inspect, who may rig, who may signal, and when a more formal lift plan is required. A critical or complex lift deserves more planning than a routine low-consequence move.

Manual material handling is also part of the risk picture. Awkward reaches, heavy loads, twisting, poor grips, repetition, and long carries create ergonomic risk. Mechanical aids can reduce force, but they must be available, maintained, and practical. A cart that is always blocked by stored materials will not control risk.

ASP questions often include mixed hazards. A forklift moves a chemical tote through a pedestrian aisle near a dock. A crane lift crosses an occupied work zone. A pallet rack is damaged but remains loaded. The best answer usually pauses the move, evaluates the load and path, separates people, inspects equipment, communicates roles, and corrects defects before proceeding.

Material handling program checks include:

• Operators and riggers are trained for their equipment and tasks.
• Equipment is inspected and unsafe equipment removed from service.
• Load weight, stability, route, and landing area are known.
• Pedestrians are separated or controlled.
• Exclusion zones are established for overhead loads.
• Maintenance, charging, fueling, and storage hazards are addressed.
• Near misses and damage reports trigger review.